Apparatus for manufacturing metallic elements



SEARCH ROM Nov. 16, 1954 A. J. L Ewls 2,694,323

APPARATUS FOR MANUFACTURING METALLIC ELEMENTS Original Filed April 30, 1945 3 Sheets-Sheet l N u l2/iff @BIL-s mili l.' a

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Nov. 16, 1954 A. .1. I Ewls 2,694,323

APPARATUS FOR MANUFACTURING METALLIC ELEMENTS Original Filed April 30. 1943 5 Sheets-Sheet 2 NGV. 16, 1954 A- LEw|s 2,694,323

APPARATUS FOR MANUFACTURING METALLIC ELEMENTS Original Filed April 30, 1943 3 Sheets-Sheet 3 United States Patent O APPARATUS FOR MANUFACTURING METALLIC ELEMENTS Arthur J. Lewis, Stratford, Conn., assignor to The Antoyre Company, Oakville, Conn., a corporation of Connecticut Continuation of application Serial No. 485,210, April 30, 1943. This application January 24, 1950, Serial No. 140,270

1 Claim. (Cl. 80-27) This invention relates to methods and apparatus for manufacturing metallic elements or bars of novel character, more particularly to metallic elements or bars for forming towel bars and similar fixtures for bathroom and kitchen use, and the invention has for an object the provision of improved metallic elements or bars of this character and methods and apparatus for manufacturing the same.

In a copending application of Philip B. Shailer, Serial No. 485,188, filed April 30, 1943, and entitled Fixture Element, now Patent No. 2,356,703 dated August 22, 1944, there is disclosed and claimed a fixture element or bar having angularly-related faces and a generally diamond-shaped cross section, the faces of the bar being concave about axes parallel to the bar and having smooth reliecting faces. Although the invention described and claimed in the said Shailer application may be embodied in bars formed from various materials, it is desirable, in the manufacture of low cost fixtures and the like, to form the bars from relatively inexpensive and readily weldable metals, such as steel, which are in themselves subject to corrosion or rusting, and to then render the bars rust-proof and corrosion-proof by the application to the surfaces thereof of a continuous rust-proof coating, such for example as a layer of non-corrosive metal electroplated onto the surfaces of the steel bar or element.

It has been found that the character of the surface obtained by an electroplating operation depends not only upon the plating metals and the plating processes employed, but also to a large degree upon the character of the surface to which the plating is applied. Flaws, pores, or imperfections in the original base surface seriously detract from the appearance of the plated surface. It 1s of course fundamental that to achieve a rust-proof article or element the rust-proof coating applied thereto must be substantially continuous, that is, free from pores or cracks,

and it has been found that pores which exist in the original surface will not, due to the nature of the electrolytic action involved, be closed or lilled by the plating metal when such a surface is electroplated.

It is accordingly a further object of the present invention to provide economical and improved methods and apparatus for manufacturing xture elements or bars of the general character disclosed in the said Shailer application, and for imparting to such bars or elements improved surface characteristics whereby, upon plating, there will be obtained an effectively rust-proofed bar or element having an improved appearance.

It is a further object of the invention to provide a method for forming a metallic element or fixture bar having a surface of improved and distinctive textured appearance and improved resistance to corrosion.

In accordance with one embodiment of the present invention, the steel wire or bar stock from which the fixture bars are to be formed is subjected to a progressive squeezing, rolling and cold working through the action of a series of opposed, angularly-related, positively-driven forming surfaces, by virtue of which the surface of the stock is continuously kneaded and wiped as it moves into and out of forming engagement with the angularlyrelated forming surfaces. Successively acting forming surfaces are disposed to progressively reduce the stock and form it to the desired cross section.

This progressive forming action is preferably effected through the use of a forming machine which comprises a series of pairs or stands of opposed forming rolls. Each forming roll of the series presents two angularly-related 2,694,323 Patented Nov. 16, 1954 convex forming surfaces arranged to provide a groove around the roll, and each of the forming surfaces is preferably substantially identical withl the other forming surfaces in the series. In the particular embodiment illustrated in the drawings, the opposed co-operating rolls of each pair are operated with zero clearance and the angularly-related forming surfaces of successive pairs of rolls are axially spaced progressively less in the successive pairs of rolls, so that the forming surfaces operate progressively to squeeze and knead the stock to effect the desirled shaping and reduction in the cross section of the stoc For a more complete understanding of the invention reference should now be had to the drawings, in which:

Fig. l is a side elevational view showing somewhat diagrammatically an apparatus embodying the present lnventlon;

Fig. 2 is a fragmentary sectional plan view on a somewhat enlarged scale taken substantially along the horizontal center line 2-2 of the apparatus of Fig. l;

Fig. 3 is an enlarged sectional elevational view taken on the line 3-3 of Fig. l;

Figs. 4 and 5 are enlarged fragmentary views showing the iinal operation to which the stock is subjected in forming the improved bars or elements embodying the invention;

Fig. 6 is a perspective view of a towel bar construction employing a bar or element manufactured in accordance with and embodying the invention; and l:.Fig6. 7 is an enlarged sectional view of the bar of Referring now to the drawings, the apparatus shown in Figs. 1 to 6, inclusive, for carrying out the methods and producing the improved elements embodying the invention, will irst be described. As shown in Figs. 1, 2, and 3, the apparatus comprises a plurality of stands or pairs of forming rolls, indicated generally by the reference numerals 10, 12, 14, 16, 18, 20, and 22, which are arranged in a straight line for successive operation on a continuously moving wire or bar, the various stands preferably being bolted or otherwise being secured to a base member 26. All of the stands or pairs of rolls are similar in construction, and accordingly only the first stand 10 will be described in detail, the other stands being described only insofar as they differ from stand 10.

Referring particularly to Figs. 2 and 3, the stand 10 comprises co-operating upper and lower roll assemblies having cooperating forming surfaces which define a substantially diamond-shaped aperture through which the stock passes during the forming operation. The upper roll assembly comprises a shaft 32 journaled at one end m a bearing block 33 vertically slidable in spaced apart guide members 34 carried by the base 26. Mounted on an intermediate reduced portion of the shaft 32 and secured thereto by a suitable key 35 is a pair of identical forming members 36 which are oppositely disposed, and, as shown best in Fig. 3, present angularly-related convex peripheral forming surfaces 38. The forming members 36 in the stand 10 are separated, as shown, by an annular shim or spacing member 40.

The forming members 36 and the interposed spacing member- 40 are maintained firmly in engagement with each other and with a suitable shoulder 44 on the shaft 32 by means of a sleeve 45, a washer 46, and a nut 47, which later is threaded, as shown, on an extending end of the shaft 32. The sleeve 45 is journaled in a bearing member 52 which is mounted between, and vertically slidable with respect to, suitable guides 54 similar to the above described guides 34.

The lower roll assembly of the stand 10 is substantially identical with the upper roll assembly, and includes similar forming members 56 separated by a spacing member 60 which correspond to the forming and spacing members 36 and 40 respectively of the upper roll assembly, the members 56 and 60 being similarly mounted and keyed to a shaft 62 for rotation therewith. The shaft 62 includes a shoulder 66, and a suitable spacing member 64 is positioned between this shoulder and the adjacent forming member 56, all of the parts being held firmly in position on the shaft by a sleeve 68 and a suitable nut 70.

The shaft 62 is journaled at one end for rotation in a bearing member 71 which lies between the vertical guides 34 and is keyed to a suitable base plate 72 by a key 74, the base plate 72 being mounted on the base member 26 which supports all of the stands. The above referred to sleeve 68, through which the forward end of the shaft 62 extends, is journaled as shown in a bearing member 76 which lies between the other pair of guides 54, the bearing member 76 being held in place by a lug 78 secured by a bolt 80 to the base plate 72.

Adjustment of the upper and lower roll assemblies to provide the desired zero clearance between the respective rolls or forming members so as to compensate for bearing wear and deflection under load is accomplished by a pair of adjusting members 82 mounted in threaded engagement with a supporting member 86 extending between the upper ends of the vertical guides 34 and 54. The lower ends of the members 82 abuttingly engage suitable hardened buttons or pressure members 90, the shank portions of which extend into suitable holes 94 in the bearing members 33 and 52 respectively. Simultaneous adjustment of the members 82, to exert pressure on the upper surfaces of the bearing members 33 and 52, is effected by suitable gears 102 and 103 mounted on the upper ends of the adjusting members and arranged to mesh with a common driving gear 104 carried by a vertical shaft 105 journaled in and extending upwardly from the supporting member 86. The upper end of the shaft 105 is squared, as indicated by the reference numeral 107, for engagement by a suitable adjusting Wrench or tool. As shown, a guide member 108 bolted to the supporting member 86 slidably engages a recess 112 in the bearing member 33 to restrain the bearing member against endwise movement while permitting vertical adjustment thereof.

In carrying out the forming operation, the upper and lower roll assemblies are positively driven at predetermined speeds by suitable gearing which comprises a gear 114 on the extending end of the shaft 32 arranged to mesh with a similar gear 116 on the shaft 62 of the lower roll assembly. A main drive shaft 118 is connected through suitable bevel gears 120 and 122 to one end of a countershaft 124 journaled in the base 26 of the ap paratus, and a spur gear 126 at the other end of the countershaft 124 meshes with a second spur gear 128 on the corresponding end of a second countershaft 130, the opposite end of which carries a spur gear 132 disposed in meshing relation with a large spur gear 133 keyed to the extending end of the shaft 62.

The co-operating forming members 36 and 56, tot gether with the spacers and 60, define a bar-receiving space which, as shown best in Fig. 3, is generally diamond-shaped, the sides of the diamonds being concave due to the convex forming surfaces 38. These forming surfaces 38 extend angularly with respect to the axes of rotation, and accordingly different portions of the surfaces 38 travel at different peripheral speeds due to the difference in radial distances from the axes. As the bar stock or wire being processed passes through the bar-receiving space due to the action of the forming surfaces thereon, it will of course travel at a linear speed less than the peripheral speed of the maximum radius portions of the forming surfaces, and greater than the peripheral speed of the minimum radius portions. Consequently, the forming surfaces exert on the surface of the bar stock being formed a pronounced wiping action which takes place at the same time that the stock or bar is being squeezed and worked.

The original stock to be formed or processed may be of any desired cross-sectional shape, but is preferably round bet, `v)use steel wire or bar stock of this form is in general less costly than other cross-sectional shapes. As the round stock passes between the forming members of the first stand or pair of rolls, the surfaces 38 squeeze and work the stock so as to form four longitudinal grooves therein. Thus portions of the metal stock will be squeezed outwardly and caused to travel transversely across the forming surfaces, and this transverse flow of the metal co-operates with the above-described wiping action of the forming surfaces to produce a definite scouring and kneading action resulting in an improved surface characterized by a marked reduction in the imperfactions and pore-like surface aws which are usually encountered in the original stock.

The successive stands or pairs of rolls 12, 14, 16, 18,

20, and 22 differ from stand 10 only in the axial spacing of the forming members 36 and 56. As shown in Fig. 2, the spacer 60, between the lower forming members 56 in the stand 10, is relatively thick, the corresponding spacing members in the second and fourth stands 12 and 16 are progressively thinner, and no spacing member is provided in the last stand 22. Of course an identical progressive decrease in the thickness of the spacers 40, provided in the upper roll sets of the respective stands, is employed, and since all of the roll sets operate with substantially zero clearance between the forming members of the upper and lower roll assemblies, the cross-sectional areas of the bar-receiving spaces progressively decrease from the first to the last stand of rolls.

A progressive elongation of the bar stock, due to the progressive decrease in cross section as it passes through the successive stands, will of course be obtained, and in order to properly provide for the consequent increase in the linear speed of travel of the Stock, the successive pairs or stands of rolls are driven at progressively increasing speeds. Each stand of rolls is driven from the main shaft 118 by a gearing arrangement identical to that employed for stand 10, except that the gear ratio of the spur gears, between the countershafts corresponding to the countershafts 124 and 130, is varied to drive the rolls in each stand at a constant speed which is higher by a predetermined amount than the speed of the preceding stand.

The action of the nal stand or pair of rolls 22 is illustrated in Figs. 4 and 5, wherein a section of a bar or rod is shown as it passes through the rolls. The portion of the rod 140 to the right of the rolls, as viewed in Fig. 4, has not yet been completedly formed to the desired concave-sided diamond-shaped cross section, but still includes unformed portions not directly acted upon by the forming surfaces. As the roll enters the barreceiving space between the forming members of the upper and lower roll assemblies, the sides thereof will be further squeezed together, and the excess metal displaced by the squeezing operation liows across the faces of the forming members, as heretofore described, so that the bar assumes the desired cross section shown in Fig. 5. Upon passing from the last stand of rolls, the continuously moving bar preferably passes to a suitable flying shear or cut-off mechanism, indicated generally by the reference numeral 141 in Fig. l, which automatically operates to sever the finished bar into prede-. termined suitable lengths, and it will of course be understood that the lengths of concave-sided diamondshaped bars thus provided may then be subjected to such other bending or plating operations as may be desired to form a xture or other article` It will be clear from the foregoing, that as the bar is passed from one station to another, a burnishing action will occur due to the squeezing operation and due also to the wiping action caused by relative movement between the forming surfaces and the bar. For example, at the first station, the forming surfaces 38 deform the bar to provide four longitudinal grooves therein, thus obtaining four concave burnished surfaces of predetermined width. At succeeding stations, the width of such burnished surfaces is successively increased, the metal of the bar being caused to always flow in the same direction at each station. Hence at each successive station, the burnished surfaces previously obtained remain substantially undisturbed, except for a further burnishing thereof and a successive increase in the width of such burnished surfaces. The metal which is caused to flow toward the apices of the bar to effect the increase in width of the burnished surfaces, is flowed in the same direction at the successive stations and comes from the central portion of the bar. With such an arrangement, the bar surfaces are successively burnished throughout the run so that the final surfaces are highly textured and exceedingly smooth. The invention is thus a definite improvement over prior devices which work the stock in successive directions at right angles to each other where the surfaces formed at alternate stations are reworked and destroyed at the intermediate stations. No multiple burnishing occurs in the prior devices, it being obvious that the surface of the finished product would be due solely to action of the last station of the machine.

As has been heretofore pointed out, the corresponding forming surfaces of the rolls at all stations are sub stantially identical with each other. The only difference between the successive bar receiving spaces resides in the axial spacing of the forming rolls 36 and 56 due to the progressive decrease in the thickness of spacers 40 and 60. It is pointed out however, that the diameters of the spacers 40 and 60 are such that the peripheral portions thereof never engage the bar during operation of the machine. Thus, the aforementioned spacers do not form any part of the forming surfaces. This will be clear from an inspection of Fig. 4 illustrating the final station which does not include any spacers. It will be observed from this figure that the bar 140 is only forced into the bottom of the roller groove as it passes through this final station. The portion of the bar 140 to the right of the roller axis clearly shows the shape of the bar as it leaves the next to the last set of rollers.

In Figs. 6 and 7 there is shown, for purposes of illustration, one form of fixture or towel bar utilizing for the towel-supporting portion thereof an improved metallic element or bar manufactured in accordance with the present invention. The bar 142, which is shown in cross section in Fig. 7, is bent as shown to provide supporting legs 143 which are welded or otherwise secured to suitable wall-engaging brackets 144. The bar 142, having concave sides, is preferably disposed as shown in Fig. 7 with the long diagonal of the diamond extending vertically, whereby an impression of massiveness and an improved over-all appearance is obtained, as more fully pointed out in the said Shailer application.

It will of course be understood that the abovedescribed methods and apparatus are not limited to the formation of steel rods or bars, but may be used with various metals or combinations thereof. The combined cold working and shaping of the metal, the transverse ow of the displaced metal across the forming surfaces, and the scouring and wiping action produced by the different peripheral speeds of portions of the forming surfaces, co-operate to produce a kneading action resulting in a distinctive textured wrought appearing surface which, by reason of the concave shape of the sides of the bar, gives a unique and pleasing highlight effect. Furthermore, surface aws, scratches, and even corrosion or rust, which may have been present on the original bar stock, will be removed or reduced to a surprising degree, and consequently the tinished bar presents a highly satisfactory surface for subsequent plating operations, the character of the base surface to which the plating is applied being largely determinative, as heretofore indicated, of the final character of the plated surface.

1n some cases it may be desirable to provide the original bar stock with a coating of corrosion-resistant metal, for example a coating of copper, prior to the final forming operation. Plating the bar with copper will not, as heretofore indicated, close or ll the pores in the base stock, but, when the copper plated rod is subjected to the action of the forming rolls, the transverse ow of metal across the rolls and the combined scouring and kneading action are effective to work the copper coating in such a manner as to provide a smooth, textured impervious coat in which pores or other aws, resulting from imperfections in the base stock, are substantially worked out or covered over by the copper.

T'he copper coating may, if desired, be applied to the original stock before subjecting it to any rolling operation, or it may be applied at a point in the process after the base stock has passed through some of the forming rolls.

It will now be apparent that the present invention constitutes a distinct advance in the manufacture of metallic elements or bars of the type suitable for the construction of fixtures such as towel bars. The method of processing the metal stock is simple, yet effective to form a bar or metallic element of distinctive and pleasing appearance, and the apparatus, which involves identical forming elements to provide the convex forming surfaces at each stand of rolls with all of the stands operating at zero clearance, is economical to construct and operates to accurately form the bars at a high production rate without requiring careful adjustments or skilled attention. Finally, the method and apparatus, as heretofore pointed out, provide a scouring action on the surface of the bar being processed so that a final product of improved character and appearance is obtained.

While I have shown and described particular embodiments of my invention, it will be understood, of course, that I do not wish to be limited thereto since many modifications may be made, and I, therefore, contemplate by the appended claims to cover any such modifications as fall within the true spirit and scope of my invention.

This application is a continuation of my application Serial No. 485,210 filed April 30, 1943, now abandoned.

What is claimed is:

Apparatus for forming from metal bar stock a rod of generally dngndhaped cross-section having apices in vertical an horizontal longitudinal planes with the four sides of the diamond-shaped section formed with concave rooves, comprising a lit of n itudinall s ace roll stands arranged in a straight line, eacn fl'sim'tn'ds-including upper and lower parallel roll shafts and the roll shafts of all the roll stands being parallel with each other, a rod forming roll assembly secured to each of said roll shafts, and the roll assemblies of the upper and lower shafts of each stand being arranged in rod forming relation, each of the roll assemblies of both the upper and lower roll shafts of each stand consisting of a pair of identical annular forming members, each having a convex peripheral forming surface and the surfaces of a pair arranged in opposed relationship and constituting one-half the roll pass, each of the roll assemblies including an annular spacing disk located between each pair of opposed annular forming members to enlarge the roll pass, the annular disks at the first stand being a predetermined thickness, and the thickness of the disks of each succeeding stand being progressively reduced to gradually reduce the width of the pass.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 236,696 Reese Jan. 18, 1881 327,728 Schultz Oct. 6, 1885 421,625 Sims Feb. 18, 1890 446,498 Williams Feb. 17, 1891 1,514,405 Talbot Nov. 4, 1924 FOREIGN PATENTS Number Country Date 5,358 Sweden Aug. 1l, 1894 

